Limb protectors, methods of making and methods of using

ABSTRACT

Disclosed herein are limb protectors with one or more conformal, articulating pads disposed on a compression sleeve. The pads comprising circumferential coverage of greater than 90 degrees and improved impact resistance.

CROSS REFERENCE TO RELATED CASES

This application is a Continuation-in-Part under 35 U.S.C. §120 ofcommonly-owned and co-pending U.S. application Ser. No. 13/208,229,filed on Aug. 11, 2011, and also claims priority under 35 U.S.C. §119(e)to commonly-owned and co-pending U.S. Provisional Application No.61/982,317, which was filed on Apr. 21, 2014. The subject matter of eachof the foregoing applications is incorporated herein by reference in itsentirety.

TECHNICAL FIELD

The present disclosure relates to improved limb protectors and, inparticular, to limb protectors with improved circumferential coverageand improved impact resistance.

BACKGROUND

The use of protective limb guards in athletics and extreme sports iswell known. For example, shin guards have been used to protect the frontsurface of a user's lower leg in athletics for some time. Football(American soccer) shin guards are a single piece of hard plastic that iscurved to fit over a user's shin bone, and is worn underneath andsecured in place over the shin by a long sock. Variations andmodifications of the traditional shin guard include attaching a stirrupto the shin guard, to prevent the shin guard from moving up the shinduring use.

The specifications for the guards that may be used by players is oftendetermined by various associations and/or regulatory bodies. However,professional players may have discretion regarding the selection ofprotective gear, and may prefer to minimize the size of hard plasticshin guards, because they can be uncomfortable and interfere with theirperformance. Therefore, many professional players select smaller sizedhard plastic guards, to minimize the surface area of the guard, andimprove comfort and ease of play. However, doing so leaves the playerexposed to more injuries.

There is a need for improved limb protection in athletics and otherareas.

SUMMARY

The present disclosure is directed to, in one embodiment, a limbprotector that comprises a compression sleeve and one or more conformal,articulating pads disposed on the sleeve. The one or more pads cancomprise circumferential coverage of greater than 90 degrees. The padscomprise polyurethane foam with a density ranging from about 8 poundsper cubic foot (pcf) to about 30 pcf and a thickness ranging from about0.2 inches to about 1 inch.

The present disclosure is directed to, in another embodiment, a limbprotector, comprising a compression sleeve and one or more conformal,articulating pads disposed on the sleeve, the one or more padscomprising circumferential coverage of greater than 90 degrees. The padsare constructed to prevent the transmission of force of no greater than50 kiloNewtons (kN).

The above described and other features are exemplified by the followingfigures and detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other features and advantages will be apparent fromthe following more particular description of exemplary embodiments ofthe disclosure, as illustrated in the accompanying drawings, in whichlike reference characters refer to the same parts throughout thedifferent views. The drawings are not necessarily to scale, emphasisinstead being placed upon illustrating the principles of the disclosure.Referring now to the figures, which are exemplary embodiments, andwherein like elements are numbered alike:

FIG. 1 shows a limb protector according to the present disclosure, in anextended position;

FIG. 2 shows the limb protector of FIG. 1, in a retracted position;

FIG. 3 shows the inside surface of the limb protector of FIG. 1;

FIG. 4 shows another embodiment of a limb protector according to thepresent disclosure, in an extended position;

FIG. 5 shows the limb protector of FIG. 4, in a retracted position;

FIG. 6 show another embodiment of a limb protector according to thepresent disclosure, which is similar in construction to the limbprotector shown in FIG. 4, and additionally includes a foot stirrup, inan extended position;

FIG. 7 shows another embodiment of a limb protector according to thepresent disclosure, in which the pads have angled edges, in an extendedposition;

FIG. 8 shows the limb protector of FIG. 7, in a retracted position;

FIG. 9 shows another embodiment of a shin guard according to the presentdisclosure, in an extended position;

FIG. 10 shows the limb protector of FIG. 9, in a retracted position;

FIG. 11 show another embodiment of a limb protector according to thepresent disclosure; and

FIG. 12 shows a cut-away view of another embodiment of a lower limbprotector, with a cover over the padding, and a sock attached to thelower end.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present disclosure is directed to improved impact absorbing andcushioning limb protectors (hereinafter “protectors”) to be worn duringany activity in which individuals are susceptible to limb injuries, suchas in athletics, construction, military, and the like. The constructionof the present protectors is rugged, durable, and able to withstand thetemperatures, detergents and mechanical action used in industrial and/orcommercial laundering, unlike other protectors, which may degrade undersuch harsh conditions.

The present protectors are lightweight, flexible and articulating, andprovide improved impact-resistance and reduced force transmission to auser, in addition to being aesthetically pleasing and durable. As usedherein, the term “flexible,” means the ability of the pad to move bybending, twisting, flexing and/or stretching, and the like.“Articulating,” as used herein, means a structure that comprises one ormore joined segments, i.e., not a sheet of uniform thickness without anysegments. The segments may be joined by a variety of techniques,provided that the segments are fixed in relation to one another.“Conformal,” as used herein, means matches the shape of the limb.“Impact resistant,” or “impact resistance,” as used herein, means thatthe surface of the padding is resistant to being torn or perforated.“Transmitted force,” as used herein, means the force transmitted to thepad during a spherical impactor test.

For ease of illustration, the limb protection protectors of the presentdisclosure will be illustrated with reference to a lower leg protector,or shin guard. Although described herein with reference to a lower legprotector, it will be apparent to those of ordinary skill in the artthat the protector may be adapted to any limb or body part that requiresprotection.

In some embodiments, the limb protectors according to the presentdisclosure can include a tubular compression sock, sleeve or stirrup,constructed to receive and fit closely against a user's limb. For easeof illustration, unless otherwise noted, the sock, sleeve or stirrupprotectors will be referred to interchangeably hereinafter as a“sleeve.” As shown in the figures, the sleeve has opposing front andback regions and opposing inner and outer side regions.

Shin guards are often subjected to impact tests to assess the energyabsorbing and penetration resistance properties of shin guards, such asblunt impact and a stud impact tests. Blunt impact tests assess theimpact absorbing properties of the guard. Tests typically involvedropping a striker onto the outer shell of the guard and measuring theamount of force transmitted through the guard. In Europe, two studimpact tests are used to assess the penetration resistance propertiesand the rigidity of the shin guards against football (soccer) bootstuds. Guards are assessed visually to determine if penetration throughthe inner surface has occurred. In the case of the vertical stud test,the distance that the stud has travelled over the surface of the outershell is also recorded.

Limb protectors used for more extreme conditions, such as for use bymotorcyclists, have more aggressive testing. In Europe, the protectivequalities of armor worn on the limb joints while riding a motorcycle aretested using CE EN 1621-1, which involves placing a sample over a rigidmetal hemispherical anvil with a 50 mm radius, which is in turnconnected to a rigid and massive base via a high speed force sensor. A 5kg impactor with a flat strike face 80 mm×40 mm is then dropped onto thesample from a height necessary to generate an impact speed of 4.47 m/s,which equates to an impact energy of 50 joules. During the impact, theforce transmitted through the sample to the anvil is measured by thehigh speed force transducer. The lower the force, the more protective aproduct is considered to be. To pass the standard the mean maximumtransmitted force must be below 35 kN, and no single value should beover 50 kN. The present pads meet the foregoing test criteria, dependingon the thickness and density of the pad materials.

FIGS. 1-3, when taken together, show a lower limb protector 100according to the present disclosure, with greater than 90°circumferential coverage, which can be worn over or under clothing.“Circumferential coverage,” as used herein, means the percentage of thelimb circumference that is covered by the padding, measured at thewidest circumference of the limb for which the protector is intended.The present limb protectors can provide circumferential coverage ofgreater than 90° and up to about 360°, depending on the construction ofthe protector, as will be discussed below.

As shown, limb protector 100 includes a front pad 10 and a back pad 12.Each of the front and back pads 10,12 includes an upper edge 16, a loweredge 18 and opposing first and second side edges 20, 22. In the presentembodiment, and throughout this description, the reference character “f”will be used with reference to the front pad 10 and the referencecharacter “b” will be used with reference to the back pad 12. Each ofthe first and second side edges 20 f of the front pad 10 includes aplurality of opposing, alternating projecting regions 22 f and opposingrecessed regions 24 f.

Each of the front and back pads 10,12 includes opposing inner surfaces10 i,12 i and outer surfaces 10 o,12 o. A plurality of guide channels 14is disposed on the inner surfaces 10 i, 12 i of each of the front andback pads 10,12. The guide channels may be, for example, fabric attachedto a liner on the pads.

A connector 26 f is attached at both ends to the opposing projectingregions 24 f of the front pad 10. Similarly, a connector 26 b isattached at both ends to the opposing projecting regions 24 b of theback pad 12. In the present embodiment, the connectors 28 f,b areelastic straps attached by, for example, stitching, although a varietyof other materials could be used for the straps, and a variety of otherattachment techniques could be used to attached the connector to thepads, as would be know to those of ordinary skill in the art.

When assembled, the straps 28 f are disposed in the guide channels 14 bon the inside surface 12 i of back pad 12, to which they are notattached; and straps 28 b are disposed in the guide channels 14 f on theinside surface 10 i of front pad 10, to which they are not attached.

In use, the projecting regions 24 f of the first side edge 20 correspondto the recessed regions 26 b of the second edge 22, and the recessedregions 26 of the first side edge 20 correspond to the projectingregions 24 of the second edge 22, to define a space “S” between theedges. In use, the spacing S increases or decreases in response to thestretching or contracting of the limb protector. In use, a user canexpand the limb protector to slide the protector onto their lower limb,and when positioned properly on the lower limb, the user can release thelimb protector, such that the straps retract and the protector conformsto the user's lower limb. FIG. 1 shows the limb protector 100 in anexpanded position, with a first spacing S₁, and FIG. 2 shows the limbprotector 100 in a retracted position, with a second spacing S₂.

The at least one back pad 30 is positioned on the sleeve to cover theback side of a user's calf, which minimizes or prevents injury to thefibula as a result of a lower leg impact, particularly from behind theuser. Limb protector 100 also may include an optional front pad 40disposed on the front region of the sleeve, in order to provideprotection for the tibia bone.

In the present embodiment, the edges of the front and back pads areconstructed to have corresponding saw tooth configurations, such thatthe spacing S increases or decreases in response to the stretching orcontracting of the sleeve.

FIGS. 4-5 shows another embodiment of a limb protector 200 according tothe present embodiment. Limb protector 200 includes a compression sleeve30 to which pads are attached; the pads have a sleeve 30 a similarconstruction to protector 100. In the present embodiment, one or both ofthe pads are attached to the compression sleeve 30 at a distance fromthe edges of the pads, such that all or a portion of the pad edgesremain free of attachment to the sleeve 30. In the present embodiment,the spacing S increases or decreases in response to the stretching orcontracting of the sleeve, and of the straps.

In the present embodiment, the front and back pads 10,12 are attached tothe sleeve by, for example, stitching at the upper and lower edges ofthe pads. The stitching is depicted by zig-zag lines. The upper strap isare attached to the upper side edge of the front pad by stitching, andthe strap extends underneath the back pad. Similarly, the lower strap isattached to the lower side edge of the back pad by stitching, and thestrap extends underneath the front pad. Optionally, both straps can bedisposed in a guide channel, as shown in the previous embodiment, formedon the back of the pads or on the compression sleeve, if desired.

FIG. 6 shows another embodiment of a limb protector 300 according to thepresent embodiment. Limb protector 200 has a similar construction tothat of limb protector 200, and additionally includes a stirrup 40, andopposing left and right ankle pads 50 disposed on the stirrup, adjacentto the ankle.

FIGS. 7-8, when taken together, show another embodiment of a limbprotector 400 according to the present disclosure, without a saw-toothside edge. In the present embodiment, the limb protector includes atubular compression sleeve 30 having the same construction as theprevious embodiment, and front and back pads 10,12. The side edges ofpads 10,12 are angled with respect to axis “A,” and the edges of thepads are adjacent to and spaced apart from each other by spacing “S,”which varies, as previously described.

FIG. 9 shows another embodiment of a lower limb protector 500 accordingto the present disclosure 100. As in previous embodiments, limbprotector 500 includes a compression sleeve 30 and front and back pads10,12 disposed on the sleeve 30.

FIG. 11 shows another limb protector 600, similar in construction tolimb protector 500, but also including a stirrup 40, and opposing anklepads 50.

FIG. 12 shows another embodiment of a limb protector 700 according tothe present disclosure, which includes a tubular compression sleeve 30having the same construction as protector 200 (see FIG. 4). In thepresent embodiment, limb protector 700 includes a foot portion 60extending from the sleeve 30, and a sock overlay 70 connected to thesleeve by a variety of means e.g., by stitching, hook and loop tape,zipper, and the like. In the present example, the sock overlay 70 isattached to the sleeve at the ankle region, by stitching, and can beremovably attached to the sleeve at the ankle region and at the upperedge of the sleeve using, for example, hook and loop tape. In use, thesock overlay 70 can be disposed such that the pads are covered by theoverlay, and when not in use, it can be removed from the limb protectorcompletely, or pulled down to the ankle region.

The sock overlay may have any aesthetic design intended to appeal to aconsumer. For aesthetic purposes, the sleeve, pads and overlay may bethe same or different, and also may include text and/or graphics.

Suitable materials for the sleeves can comprise any material capable ofproviding sufficient elasticity to prevent tearing and/or stretchingwhen a force is applied thereto, and that is capable of withstanding theenvironment in which it is intended to be used (e.g., repetitivedeformations such as twisting, bending, flexing, stretching, and thelike), without substantial degradation. The sleeves may be constructedwith one or more materials with varying elasticity in order to allowincreased expansion of the spacer region “S” when a user is putting onthe protectors, or during use, without interference from the fixed pads.

It may be desirable for the pads to be lightweight, and in suchinstances, the pads may comprise a foam material, such as a low-densityfoam material. Examples of suitable low-density foams include polyesterand polyether polyurethane foams. In some instances, it may be desirablefor the pads to be capable of providing impact resistance. In suchinstances, various types of impact absorbing materials have been foundsuitable for the pads, particularly energy absorbing or rate dependentmaterials, including foams.

Optionally, such materials can be made water resistant or waterproof bycoating the material with a water resistant or waterproof coating. Thiscan be desirable for open cell foams in particular, to minimize orprevent moisture absorption by the foam. A variety of materials can beused to coat such materials, and the coating can be done using a varietyof techniques such as, but not limited to, spray coating, spin coating,dipping, and the like.

One example of a suitable rate dependent foams is available from RogersCorporation under the brand names PORON® and PORON XRD®, which are opencell, microcellular polyurethane foams. It can be desirable for suchfoams to have a density ranging from about 5 to about 35 pounds percubic foot (pcf), more particularly from about 10 to about 30 pcf, andmore particularly still from about 15 to about 25 pcf.

Materials for and methods of making the some materials that are usefulfor the present protectors are disclosed in commonly owned andco-pending U.S. Patent Publication Nos. 2012/0084896, filed on Aug. 11,2011; each of which is incorporated herein by reference in its entirety.In addition to the foregoing, suitable materials for the foregoinglayers and the adhesive (if used) are disclosed in the afore-mentionedpatent applications, and in U.S. Publication Nos. US 2008/0034614 and US2009/0255625, which also disclose techniques for manufacturing thepresent cushion inserts; each of the foregoing publications isincorporated herein by reference in its entirety.

In any of the foregoing embodiments, the pads and/or straps may beattached to the sleeve by a variety of techniques, such as stitching,welding, gluing, heat-sealing, and the like. Alternatively, the sleevescan comprise pockets for receiving the pads and having a size, shape andthickness corresponding to the size, shape and thickness of the pads. Inuse, the pads may be interchangeably disposed in the pockets. After use,the pads can be removed, such that they can be removed and interchangedwith pads having different functional characteristics, depending on theuser's needs.

The size, shape, thickness and material composition of the pads may bevaried, depending on a number of factors including, but not limited to,desired amount of flexibility, articulation, impact resistance,transmitted force, circumferential coverage, and the like.

All of the foregoing thicknesses, widths, distances and spacings mayvary, as desired or necessary to provide a protective or comfortableeffect. The thickness of pads may be varied as desired, but it isdesirable for the thickness to be minimized while still being sufficientto protect the limb from impact.

The pads may have any shape or configuration as is desired to achievethe desired functional advantages of improved impact protection, reducedforce transmission and the aesthetic design intended to appeal to aconsumer. The size, shape, quantity, configuration and location of thepads on the sleeves may be varied as desired in order to achieve theforegoing objectives. For aesthetic purposes, the sleeve, pad and/oroverlay may be the same or different, may be clear, opaque and/orcolored, and also may include text and/or graphics.

Unless defined otherwise, technical and scientific terms used hereinhave the same meaning as is commonly understood by one of skill in theart to which this disclosure belongs.

It should be noted that the terms “first,” “second,” and the like hereindo not denote any order or importance, but rather are used todistinguish one element from another, and the terms “a” and “an” hereindo not denote a limitation of quantity, but rather denote the presenceof at least one of the referenced items. Similarly, it is noted that theterms “bottom” and “top” and “inner” and “outer” are used herein, unlessotherwise noted, merely for convenience of description, and are notlimited to any one position or spatial orientation. In addition, themodifier “about” used in connection with a quantity is inclusive of thestated value and has the meaning dictated by the context (e.g., includesthe degree of error associated with measurement of the particularquantity).

Unless defined otherwise herein, all ranges disclosed herein areinclusive and combinable (e.g., ranges of “up to about 25 weight percent(wt. %), with about 5 wt. % to about 20 wt. % desired, and about 10 wt.% to about 15 wt. % more desired,” are inclusive of the endpoints andall intermediate values of the ranges, e.g., “about 5 wt. % to about 25wt. %, about 5 wt. % to about 15 wt. %”, etc.). The notation “+/−10%means that the indicated measurement may be from an amount that is minus10% to an amount that is plus 10% of the stated value.

Finally, unless defined otherwise, technical and scientific terms usedherein have the same meaning as is commonly understood

While the disclosure has been described with reference to an exemplaryembodiment, it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted forelements thereof without departing from the scope of the disclosure. Inaddition, many modifications may be made to adapt a particular situationor material to the teachings of the disclosure without departing fromthe essential scope thereof. Therefore, it is intended that thedisclosure not be limited to the particular embodiment disclosed as thebest mode contemplated for carrying out this disclosure, but that thedisclosure will include all embodiments falling within the scope of theappended claims.

What is claimed is:
 1. A limb protector, comprising: a compressionsleeve; one or more conformal, articulating pads disposed on the sleeve,the one or more pads comprising circumferential coverage of greater than90 degrees; wherein the pads are adapted to prevent the transmission offorce of no greater than 50 kiloNewtons (kN).
 2. The limb protector ofclaim 1, the one or more pads comprise a circumferential coverage ofgreater than 135 degrees.
 3. The limb protector of claim 1, the one ormore pads comprise a circumferential coverage of greater than 180degrees.
 4. The limb protector of claim 1, wherein the one or more padscomprise a circumferential coverage of greater than 225 degrees.
 5. Thelimb protector of claim 1, wherein the one or more pads comprise acircumferential coverage of greater than 270 degrees.
 6. The limbprotector of claim 1, wherein the one or more pads comprise acircumferential coverage of greater than 315 degrees.
 7. The limbprotector of claim 1, wherein the one or more pads comprise greater than315 degree circumferential coverage.
 8. The limb protector of claim 1,wherein the one or more pads each comprise a side edge, and wherein inuse, the side edges are spaced apart by less than ½ inch.
 9. The limbprotector of claim 1, wherein the one or more pads each comprise a sideedge, and wherein in use, the side edges are spaced apart by less than 1inch.
 10. The limb protector of claim 1, wherein the one or more padseach comprise a side edge, and wherein in use, the side edges are spacedapart by less than 1½ inches.
 11. The limb protector of claim 1, whereinthe one or more pads comprise polyurethane foam in a density range ofabout 8 pcf to about 30 pcf.
 12. The limb protector of claim 1, whereinthe one or more pads comprise polyurethane foam in a density range ofabout 18 pcf to about 25 pcf.
 13. The limb protector of claim 1, whereinthe one or more pads comprise polyurethane foam at a thickness of about0.2 inches.
 14. The limb protector of claim 1, wherein the one or morepads comprise polyurethane foam at a thickness of about 0.3 inches. 15.The limb protector of claim 1, wherein the one or more pads comprisepolyurethane foam at a thickness of about 0.4 inches.
 16. The limbprotector of claim 1, wherein the one or more pads comprise polyurethanefoam at a thickness of about 0.5 inches.
 17. The limb protector of claim1, wherein the one or more pads comprise polyurethane foam at thicknessof about 0.6 inches.
 18. The limb protector of claim 1, wherein thecircumferential coverage is continuous.
 19. The limb protector of claim1, wherein the one or more pads are unitary.
 20. A limb protector,comprising: a compression sleeve; one or more conformal, articulatingpads disposed on the sleeve, the one or more pads comprisingcircumferential coverage greater than 90 degrees; wherein the padscomprise polyurethane foam with a density ranging from about 8 poundsper cubic foot (pcf) to about 30 pcf and a thickness ranging from about0.2 inches to about 1 inch.